Welding International

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Mechanical and microstructural properties of

submerged arc weldments with high heat input

Jorge Carlos Ferreira Jorge, Luis Felipe Guimarães de Souza, Erick de Souza
Marouco, Olavo Ribeiro dos Santos Filho & Jorge Luiz Coutinho Diniz

To cite this article: Jorge Carlos Ferreira Jorge, Luis Felipe Guimarães de Souza, Erick de Souza
Marouco, Olavo Ribeiro dos Santos Filho & Jorge Luiz Coutinho Diniz (2017): Mechanical and
microstructural properties of submerged arc weldments with high heat input, Welding International,
DOI: 10.1080/09507116.2016.1218618

To link to this article: http://dx.doi.org/10.1080/09507116.2016.1218618

Published online: 22 Feb 2017.

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Welding International, 2017
http://dx.doi.org/10.1080/09507116.2016.1218618

Mechanical and microstructural properties of submerged arc weldments with

high heat input
Jorge Carlos Ferreira Jorgea, Luis Felipe Guimarães de Souzaa, Erick de Souza Maroucoa,
Olavo Ribeiro dos Santos Filhob and Jorge Luiz Coutinho Dinizc
a
Directorate for Research and Post-Graduate Study, Celso Suckow da Fonseca Federal Center for Technological Education – CEFET, Rio de
Janeiro, Brazil; bArinque Engineering Ltd., Rio de Janeiro, Brazil; cJDiniz Consultants and Engineering, Rio de Janeiro, Brazil

ABSTRACT KEYWORDS
The purpose of this work is to present a study of the mechanical and microstructural properties of Mechanical properties;
welded joints in carbon steel obtained by the automated submerged arc process with high heat microstructure; heat input
input, with the aim of increasing productivity in the fabrication of pipes for mooring equipment.
Joints were welded in ASTM A-572 Gr.50 steel with thickness of 25  mm by the single-pass
submerged arc process, with heat input varying from 7.8 to 14.0 kJ/mm. The joints were assessed
by Charpy-V impact testing at a temperature of 0 °C, Vickers microhardness with 1-kgf load, and
metallography of test specimens taken from the weld metal and the heat-affected zone. The
results showed that the welded joints had impact toughness above the minima required for use
in the welding of C-Mn and low-alloy steels with impact requirements of 34 J at 0 °C. A significant
increase in productivity was observed, without impairing the mechanical properties, allowing
fabrication of pipes for oil equipment with a significant reduction in fabrication time.

1. Introduction the technical requirements of strength and toughness,

combined with productivity, examines establishment of
The increase in maritime activities in the area of
the process that is able to offer the best combination of
petroleum has required larger volumes of supply of
quality and productivity. From the standpoint of produc-
high-strength materials to meet the needs of deep-water
tivity, the great advantage of the submerged arc process
exploration and production operations, where semi-
compared to the other processes is associated with better
submersible platforms are used. Gonçalves and Costa
efficiency and deposition rate, as well as the possibility of
[1] emphasize that these platforms for offshore operation
fully mechanized welding operations, avoiding the lim-
are floating units whose mooring system consists of long
itations of dependence on skilled labour [6]. However,
sections of steel mooring lines, steel cables or polyester
the advantage of the submerged arc process from the
cables, according to whether the mooring system is the
standpoint of productivity must be accompanied by an
conventional catenary system or the vertical system
analysis of the mechanical properties of the weld metal
(Figure 1) and anchors of various types for securing the
and the heat-affected zone (HAZ) produced by this pro-
lines [2–4].
cess, since improvement of productivity involves the use
Various possible types of anchors are available for
of high heat inputs, which is normally associated with
selection, such as drag anchors, vertical load anchors,
lower values of toughness in the welded joint [8–12]. In
suction piles (Figure 2). More recently, torpedo piles
this context, toughness is very important for welds in
(Figure 3) have become an important alternative in
equipment for mooring offshore production platforms,
this area of activity [1], owing to the advantageous
as a low level of toughness indicates the route for occur-
conditions for installation. Welding is the main fab-
rence of brittle fracture at low levels of stress.
rication process for this last-mentioned equipment,
The aim of the present work is to analyze the mechan-
which consists of tubular structures weighing up to
ical and microstructural properties of joints welded by
120 tons.
the submerged arc process with high heat input, to
The search for optimization of costs and time for fab-
increase productivity in the fabrication of pipes for
rication of naval and offshore equipment [5–8] has been
application in equipment used in accessories of mooring
one of the main questions in discussion of the selection
systems for oil platforms.
of welding processes and procedures, which, among

Selected from Soldagem & Inspeção. 2015 20(3) 347–358.

© 2017 Informa UK Limited, trading as Taylor & Francis Group
2   J. C. F. JORGE ET AL.

Figure 1. Diagram of the mooring system for a semi-submersible platform [1].

Notes: Sistema convencional (em catenária) = Conventional (catenary) system; Sistema para ancoragem vertical  =  Vertical mooring system; SISTEMA
CONVENCIONAL = CONVENTIONAL SYSTEM; AMARRA = MOORING LINE; CABO DE ACO OU POLIESTER = STEEL OR POLYESTER CABLE; SISTEMA TAUT-LEG = TAUT-
LEG SYSTEM; CABO DE POLIESTER = POLYESTER CABLE; AMARRA OU CABO DE ACO = STEEL MOORING LINE OR CABLE; ESTACA DE SUCCAO = SUCTION PILE;
VLA = VLA.

Figure 2. Types of anchors [4].

Notes: Poita = Mooring stone; Estaca = Pile; Estaca de sucção = Suction pile; Ȃncora de arraste = Drag anchor; Ȃncoras instaladas por gravidade = Gravity-
installed anchors; Ȃncora vertical = Vertical load anchor.

2.  Materials and methods 2.2.  Welding procedure

2.1. Materials So that it would be possible to obtain welded joints in a
single pass with a weld bead profile suitable for removing
Sheets made of steel of ASTM classification A-572 Gr.50
Charpy-V impact test specimens with the notch posi-
[13] with dimensions of 500 × 250 × 25.4 mm, with the
tioned entirely in the weld metal, preliminary tests were
microstructure consisting of ferrite and pearlite shown
carried out, which indicated the use of the characteristics
in Figure 4, were used as the base material for produc-
of groove geometry shown in Figure 5.
tion of the welded joints. Table 1 presents the chemical
The sheets were preheated to a temperature of 80 °C
composition of the base material used. The filler material
and then welding was carried out in a single pass, direct
used was a combination of wire + flux of type AWS 5.17
current (DC+), stick-out of 45 mm, in the flat position
EM12K – F7A4 with solid wire, 4.0 mm in diameter.
and with the welding parameters shown in Table 2.

Figure 3. Torpedo mooring pile [3].
Notes: PARA O GUINCHO = TO THE WINCH; Guia da linha = Line guide; Solo submarine = Seabed.
Figure 4. Microstructure of the base metal.
Note: Etched with 2% nital.
2.3.  Characterization of the welded joint
Chemical analyses of the weld metals were performed
by optical emission spectrometry.
Vickers microhardness tests were carried out with a
1-kgf load on test specimens transverse to the weld bead,
with hardness scanning taking in the weld metal, HAZ
and base metal at intervals of 0.5 mm, for assessing the
behaviour of the different regions of the welded joint,
considering a variation of 5% in the results of the tests
for comparison.
Charpy-V impact tests were carried out at a tem-
perature of 0 °C, on normalized test specimens accord-
ing to standard ASTM A-370 [14] with dimensions of
10 mm × 10 mm × 55 mm, taken transversely to the
weld bead and 2 mm from the surface of the joint, three
tests being conducted for each condition analyzed, and
obtaining the mean and standard deviation of these
Table 1. Chemical composition of the base metal used.
Element C Si Mn P S
wt% 0.13 0.24 1.29 0.020 0.008
WELDING INTERNATIONAL   3
results. The notch was positioned in the plane of the
thickness and at the centre of the weld bead, as shown
in Figure 6.
Tests were also carried out with the notch positioned
on the fusion line for some selected conditions in order
to assess the behaviour of the base metal when submit-
ted to high heat inputs. As in the previous case, three
tests were carried out at a temperature of 0 °C for each
condition analyzed, on test specimens with dimensions
of 10 mm × 10 mm, taken transversely to the weld bead
and 2 mm from the surface of the joint (Figure 6).
Metallographic analysis of the welded joints consisted
of obtaining macrographs, light microscopy (LM) and
scanning electron microscopy (SEM). Specimen prepa-
ration consisted of the conventional technique of rough
polishing and fine polishing, followed by chemical etch-
ing with the reagent 2% nital. The microstructures, both
in the weld metal and in the HAZ, were assessed in a
position corresponding to the tip of the Charpy-V notch.
Quantitative analysis for microstructural constitu-
ents of the weld metals was performed by LM, and for
microphases by SEM. The point counting technique was
used in a metallographic grid with 100 points superim-
posed on the microscope screen, counting at least 10
fields selected at random for each condition, giving a
total of 1000 points per specimen.
3.  Results and discussion
3.1.  Analysis of properties
In the present work, an analysis was undertaken with
a focus on toughness, owing to the reduced variation
of mechanical strength with increase in heat input for
C-Mn weld metals [6,15].
Cr Ni Cu Nb V Ceq
0.007 0.012 0.007 0.028 0.003 0.381
4   J. C. F. JORGE ET AL.

Figure 5. Geometry of the welded joint.

Table 2. Welding parameters used.

Joint Current (A) Voltage (V) vs (mm/min) HI (kJ/mm)
A 850 34 120 14.3
B 850 34 150 11.7
C 850 34 180 9.7
D 750 31 120 11.7
E 750 31 150 9.4
F 750 31 180 7.8

Note: vs – welding speed; HI – heat input.

Figure 6. Positioning of the test specimens for impact testing.

Note: Metal de solda = Weld metal; ZTA = HAZ.

Table 3. Chemical analysis of the weld metals.

Joint C Si Mn P S Cr Mo Ni Cu Nb V Ceq
A 0.108 0.336 1.510 0.024 0.011 0.023 0.005 0.012 0.045 0.023 0.006 0.370
B 0.103 0.329 1.485 0.021 0.009 0.022 0.005 0.010 0.039 0.020 0.005 0.360
C 0.106 0.319 1.466 0.022 0.010 0.022 0.005 0.011 0.040 0.021 0.005 0.360
D 0.112 0.326 1.523 0.022 0.010 0.024 0.005 0.012 0.048 0.019 0.005 0.377
E 0.113 0.331 1.523 0.023 0.010 0.024 0.005 0.012 0.041 0.019 0.005 0.377
F 0.113 0.338 1.489 0.027 0.009 0.031 0.005 0.018 0.044 0.018 0.007 0.374

Figure 7. Macrograph of the welded joints.

Note: Etched with 2% nital.

Table 3 shows the chemical composition of the weld
metals, where it can be seen that no significant variations
in the alloying elements were found, despite the differences
found for the dilution with the base metal, which varied
from 47 to 69% (Figure 7), notably for the elements C, Si,
and Mn, the contents of which may have been reduced
by oxidation with increase in welding current [16–18]. In
addition, it should be pointed out that the carbon content
is increased somewhat, which is attributed to the effects
of dilution with the base metal, and that the manganese
content shows results around 1.40–1.50%, a value that is
considered to be adequate for C-Mn weld metals [19,20].
It can be inferred from these results that the heat
input will be the main factor contributing to formation
of the microstructure and consequently to the mechan-
ical properties.

Figure 8. Effect of the welding heat input on the microstructure
of the weld metals.
Notes: Constituent microstructural (%)  =  Microstructural constituent
(%); AFC  =  FCA; Ferrita Primaria  =  Primary ferrite; Ferrita com segunda
fase = Ferrite with second phase; Ferrita acicular = Acicular ferrite; Energia
de soldagem (kJ/mm) = Welding heat input (kJ/mm).
Figure 9. Microstructure of the weld metals (LM).
Note: Etched with 2% nital.
Figure 10. Presence of A-M constituents in the weld metals.
Note: Etched with 2% nital.
WELDING INTERNATIONAL   5
Figure 7 shows the macrograph of the welded joints
with the highest and the lowest heat input, where it can
be seen that it was possible to produce defect-free joints,
meaning that Charpy-V impact tests can be performed
in the regions of interest.
Figure 8 shows the variation in microstructure of the
weld metal with increase in heat input, together with
a weld metal obtained at 4.8 kJ/mm, which represents
the welding procedure regularly used for the welding
of mooring structures. As expected [11,16,21,22], the
proportion of acicular ferrite is at very low levels for
high heat inputs, this decrease in acicular ferrite being
accompanied by an increase in primary ferrite and fer-
rite-carbide aggregates (FCA). Moreover, as expected
[10,11,23–26], coarser structures are observed at higher
heat inputs (Figure 9). A final important aspect was the
finding of a low proportion of A-M (<3.0%) in these
weld metals (Figure 10).
6   J. C. F. JORGE ET AL.

Figure 11. Microstructures in the different regions of the HAZ.

Notes: Etched with 2% nital. Where: CGR – coarse-grained region; FGR – fine-grained region; ICR – intercritical region; SCR – subcritical region; FP – grain-
boundary ferrite; P – pearlite; FI – intragranular polygonal ferrite. Posicao/Condicao = Position/Condition; RGG = CGR; RGF = FGR; RIC = ICR; RSC = SCR.

Figures 11 and 12 provide evidence that the HAZ
showed similar behaviour to the weld metal, with a
more refined microstructure for lower heat inputs.
Furthermore, it is observed in the coarse-grained region
of the HAZ (CGR) that the refined bainitic microstruc-
ture (FS) is replaced by another with a higher proportion
of constituents with a higher transformation tempera-
ture for higher heat inputs. In fact, we observe the pres-
ence of grain-boundary ferrite (FP) and pearlite (P) at
the grain boundaries of the prior austenite, intragranular
Widmanstätten ferrite (FN) and FCA within the grains,
constituents that are normally observed in the HAZ of
carbon steels and low-alloy steels [8], replacing bainite
for higher heat inputs (Figure 12). In the other regions
of the HAZ, fine-grain regions, intercritical regions and
subcritical regions, we should point out the increase in
the proportion of intragranular polygonal ferrite (FI),
notably in the last-mentioned region.
This same behaviour was found for the results of the
hardness tests (Figure 13), both for the weld metal and
for the HAZ. It is noted that the highest hardness values
occur for the coarse-grained region of the HAZ (CGR),

Figure 12.  Microstructures of the coarse-grained region of the HAZ observed by light microscopy (LM) and scanning electron
microscopy (SEM).
Notes: Etched with 2% nital. Where: FS – bainite; FP – grain-boundary ferrite; P – pearlite; FN – intragranular Widmanstätten ferrite; FCA – ferrite-carbide
aggregates. MO = LM; AFC = FCA; MEV = SEM.
Figure 13.  Effect of welding heat input on hardness of the
welded joint.
Note: Microdureza Vickers  = Vickers microhardness; Distancia da linha de
fusao = Distance from fusion line.
with a tendency for this property to decrease in the other
positions of the HAZ, which is in agreement with the
literature [8,10,13,25]. This behaviour can be attributed
to the microstructural change noted earlier (Figure 11),
due to the increase in polygonal ferrite in the regions
farther from the fusion line.
Based on the microstructural changes, particularly
the significant decrease in the proportion of acicular fer-
rite (Figure 8) and the presence of coarser structures for
WELDING INTERNATIONAL   7
higher heat inputs (Figure 9), it can be inferred that there
is a decrease in toughness with increase in heat input
[6,9,11,15,19,22,23,27]. In this connection, Figure 14
shows a significant decrease in this property starting
from 4.8 and up to 14.3 kJ/mm. However, it is also found
that at around 7.8 kJ/mm the reduction is less significant
with a tendency towards stabilization of the toughness.
This behaviour made it possible to obtain results above
the minimum requirements [28,29] for using these weld
metals in the welding of mooring components for off-
shore platforms, despite the large dispersion found in
the results for Charpy-V impact.
These results are important, since the weld metal is
considered to be the region of the welded joint that is
of greatest concern, as it shows toughness values lower
than for the base metal [8,15,23,27].
To assess this question, since the performance of
the component depends on the behaviour of all of the
regions of this welded joint, Charpy-V impact tests were
also carried out in the HAZ for some analysis conditions.
The results of this experiment, shown in Figure 15, con-
firm the foregoing, since the values of absorbed energy
of the HAZ are higher than for the weld metal, which
presumably is associated with the microstructure that
formed. In fact, it is reported in the literature [8,23,30,31]
that C-Mn and low-alloy steels with microstructural
constituents similar to those in the present work may
8   J. C. F. JORGE ET AL.
Figure 14. Effect of welding heat input on impact strength of
the weld metal.
Notes: Energia absorvida (joules) = Energy absorbed (joules); Minimo de 34
J a 0 °C = Minimum of 34 J at 0 °C; Energia de soldagem (kJ/mm) = Welding
heat input (kJ/mm).
Figure 15. Effect of welding heat input on impact strength of
the weld metal.
Notes: Energia absorvida (joules) = Energy absorbed (joules); ZTA = HAZ;
Metal base = Base metal; Metal de solda = Weld metal; Minimo de 34 J a
0 °C = Minimum of 34 J at 0 °C; Energia de soldagem (kJ/mm) = Welding
heat input (kJ/mm).
display results for toughness in the HAZ higher than in
the weld metal, notably when high heat input is used,
which according to Borba et al. [23] reinforces the need
for a suitable choice of welding consumable not only as a
function of the design requirements, but also in relation
to the base metal and the welding procedure applied.
3.2.  Practical implications of the results
It is important to note that despite the existence of
established techniques for increasing the deposition
rate in the submerged arc process, for example the
TANDEM technique and addition of iron powder, the
purpose of the present work was to conduct a broader
analysis of the possibility of guaranteeing quality of
structures welded by the conventional high-productiv-
ity submerged arc process for industrial purposes, in
conditions different from those found in serial produc-
tion. In this situation, the constant need for movement
of personnel and change of layout for fabrication and
provision of services for various items with particu-
lar characteristics makes investment and training in
special processes economically unviable. Thus, assess-
ment of the mechanical properties of joints welded
with high heat inputs by the conventional submerged
arc process still requires more experimental evidence,
bearing in mind that the literature available for these
conditions relates to the use of the TANDEM process
[11,23,31,32].
In this connection, along with an analysis of pro-
ductivity, a metallurgical study was undertaken for the
toughness-microstructure relation of weld metal with
high heat input (up to 14 kJ/mm), so as to give technical
support for effective conclusions on adoption of relia-
ble welding procedures, based on results of Charpy-V
impact tests, besides those required by qualification
standards. In this respect, it must be borne in mind that
the weld metal is still the region of greatest concern,
since, as commented by Zhang et al. [33], the changes in
technologies for steel fabrication and rolling have given
rise to an additional challenge for welding consumables
and for joining technology.
The results for impact toughness obtained allowed
adoption of a new approved procedure, with a significant
gain in productivity. In addition, it shows that there is
also a field of research in the industrial area for C-Mn
and low-alloy weld metals, where process productivity
and automation are key points.
As already noted in earlier work [6], where a similar
procedure was assessed for welding ASTM 36 steel, it
was possible to obtain a significant improvement in pro-
ductivity, of the order of 58%. In addition, it is important
to point out that the change-over from the manual weld-
ing procedure to the fully mechanized procedure gave
indirect advantages as there was no risk of human error
or even lack of skilled labour for welding the root of the
joints, a critical point for occurrence of defects, which
allows more effective production planning. Finally, an
additional fact is that there is no need for pauses in pipe
welding for changing the process, which greatly facili-
tates specification of an optimized layout for industrial
installations.
All these questions were also verified in the present
case, it having been possible to change from an earlier
procedure with manual welding with hollow wire in the
root passes to welding entirely by the submerged arc
process, with a guaranteed improvement in productivity
of around 50%.
4. Conclusions
Based on the results presented in this work, it can be
concluded that:

(a) It is possible to perform welding of mooring
equipment for oil platforms in carbon steel,
which have additional requirements on quality,
with heat input of up to 14 kJ/mm;
(b) The weld metal was the region of the welded joint
that had the lowest toughness, so development
of consumables for this application must receive
more attention;
(c) The increase in heat input and change of the weld-
ing process gave significant gains in productiv-
ity, reducing the time for fabrication of mooring
structures by 50%.
Acknowledgements
The authors thank Fluke Engineering Ltd., and CEFET/RJ for
support in carrying out the present work.
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